Modular rough water docking system

ABSTRACT

A modular dock unit and system for making large modular dock systems is disclosed. The dock unit includes a molded floatation shell, a molded decking piece and a molded water-tight retainer ring. The floatation shell has column supports molded therein suitable for holding support members. In use, support member are placed in flanges molded into the support columns and the floatation shell rim. The water-tight retainer ring is placed on the side support members and the decking piece is opposed to the water-tight retainer. Mounting aids such as tongue and groove members are molded in opposing pieces of floatation shell, retainer and deck and secured where necessary. The dock unit also includes a boat bumper system that mates with the dock units to surround the modular dock system. When assembled, the dock unit comprises a water-tight flotation cavity protecting the internal components and providing buoyancy to the dock unit.

This application is a Continuation In Part of U.S. application Ser. No.12/979,032, filed Dec. 27, 2010, which claims priority to U.S.provisional patent application 61/290,727 filed Dec. 29, 2009 thecontents of which are incorporated herein in their entirety for allpurposes.

FIELD OF THE INVENTION

This invention is directed to floating dock units and a modular systemfor constructing floating docks.

BACKGROUND OF THE INVENTION

Floating docks are generally known and may be constructed from a varietyof materials and formed into a variety of shapes and sizes. At leastsome known floating docks include a plurality of floating units coupledtogether to form a floating dock system. Generally, the floating unitsare designed to withstand a variety of environmental and weatherconditions. More specifically, within at least some known floatingunits, pockets or cavities are defined that facilitate increasing thebuoyancy of the dock, and thus facilitate maintaining the dock afloat.

Further, at least some known floating docks systems have couplingmechanisms that enable multiple configurations of the floating membersto be assembled such that the dock can accommodate a variety of boatsizes and other uses. Generally, such coupling mechanisms includecouplers designed to facilitate ease of assembly and disassembly offloating units, and coupler receivers or sockets are designed to receivea variety of couplers and dock accessories. More specifically, within atleast some known coupling mechanisms, the couplers include multiplecomponents. Although the couplers generally ensure the floating unitsremain connected, couplers that include multiple components may increasethe assembly time of the docks and may reduce the reliability of theentire dock system.

Prior art individual unit assembly is made by using multiple parts forthe bottom section, top section and side walls. Therefore, each of theunits is subjected to individual stress at their point of assembly. Inaddition, while some floating dock units disclosed unitary floatingmembers, their means of floatation was limited and their ability fortransport and storage was greatly limited. For example, U.S. Pat. No.7,243,608 describes a modular dock unit which includes a top and abottom connected by side walls. The units are unitary pieces that arethen clad with decking members. As will be appreciated by those of skillin the art, the dock units are cumbersome and hard to store andtransport while also providing limited floatation capacity. Further, theconnection of the individual units into a multiple unit dock system isby means of connectors which allow the individual units to moveindependently of each other. Those of skill in the art will appreciatethat walking from one unit to another unit can, therefore, be difficult,especially at times when the water is rough and the weather isinclement. In addition, it should be appreciated that each connectionalso provides a point of stress between the units and is subject tobreakage and or rupture independently.

U.S. Pat. No. 6,695,541 describes modular floating dock sections. Thesections described are hollow dock units. The units are molded toinclude the top and bottom portions connected by the side walls. Theindividual units are connected to each other by male type anchors fittedinto female receiving sockets molded into the side wall of each unit.The anchors are then secured to each other using a tie-rod. While thesystem disclosed in the '541 patent directly connects the individualunits to each other, eliminating independent movement of each unit inrelation to each other, the units are bulky, hard to transport and, inaddition, the connecting anchors and tie-rod are exposed to theenvironment and, thus, subject to weather, corrosion and rupture.

Therefore, it would be advantageous to provide a modular dock systemthat eliminated independent movement between units but that alsoprovided ease of shipment and storage and which further allowedconnecting units, and hardware to be removed from exposure to theelements but also provided a secure and direct form of attachmentbetween the individual units.

SUMMARY OF THE INVENTION

A modular dock unit and system for making large modular dock systems isdisclosed. The system includes a molded floatation shell, a moldeddecking piece and a molded water-tight retainer ring. The floatationshell has column supports molded therein suitable for holdingindependent frame support members. In use, frame support members areplaced in flanges molded into the support columns and the floatationshell rim. The water-tight retainer ring is placed on the side supportmembers and the decking piece is opposed to the water-tight retainerring. Mounting aids such as tongue and groove members are molded inopposing pieces of floatation shell, retainer and deck and secured wherenecessary. The dock unit also includes side rails that mate with thedock units also by molded mounting aids. When assembled, the dock unitcomprises a water-tight floatation cavity protecting the internal framecomponents and providing buoyancy to the dock unit.

Therefore, in various exemplary embodiments, the invention disclosedherein provides a molded floatation shell including a bottom and sidewalls, a molded foam filled decking piece designed and configured to fitover the top of the floatation shell, and a molded water-tight retainerring designed and configured to fit between the decking piece and thefloatation shell. Upon securing of decking piece to the floatationshell, with the retainer ring interposed therebetween, a water-tightfloatation chamber is created. Each assembled unit thereby provides afloating dock unit.

In some exemplary embodiments, the molded floatation shell, the foamdecking piece and the water-tight retainer ring are made by rotationalmolding. In still other exemplary embodiments, the floatation shell isfurther molded to include support columns in the interior of thefloatation shell ascending from the bottom of the shell to the upper rimof the shell. In various exemplary embodiments, the columns are hollowin the interior. In these exemplary embodiments, the shells arestackable, nesting within each other such that each additional shellincreases the height of the stack by little more than the thickness ofthe shell. In various exemplary embodiments, the thickness of the shellmay be as little as about, approximately one-quarter inch up to 6″depending on the thickness of the floatation shell as a single wall partup to and including a double wall part that is also foam filled.Further, when nested together, the stacks of floatation shells areextremely space efficient and are easy to transport. However, those ofskill in the art will recognize that the floatation shell, the deckingpiece and the water-tight retainer ring can be made by any suitablemethod, including conventional molding or milling. In some exemplaryembodiments the water-tight retainer ring and the decking piece are madeusing “one-step” foam rotational molded technology or a two-step foammolded technology.

Further, while in some exemplary embodiments, the floating dock unitsare rectangular, and have dimensions of approximately 24′×4′×2′;24′×6′×2′; 24′×8′×2′; and 12′×24′×2′, those of skill in the art willrecognize that one advantage of molding the units is that they can beany size required such as circular, hexagonal, trapezoidal, etc.Therefore, there is very little limitation imposed upon the size andshape of the units disclosed according to the instant invention.

In various exemplary embodiments, the floatation shell is molded toinclude flanges disposed within side walls of the shell and the supportcolumns. The flanges are designed and configured to accept supportmembers such that when the dock unit is assembled, the support membersare securely held in place in the watertight floatation chamber by thefoam decking piece to which the support members also provide support. Instill other various exemplary embodiments, the dock unit includes amolded side rail dimensioned and configured to intercalate between thedecking piece and the water-tight ring such that when the dock unit isassembled, the side rail is securely held in place. In addition, invarious other exemplary embodiments, the molded side rail is hollowproviding a flexing side rail, thereby eliminating the need foraccessories such as boat bumpers.

In some exemplary embodiments, the invention also includes methods forconnecting the modular dock units such that the dock units can besecurely attached to each other in any desired configuration. In theseexemplary embodiments, the dock units are connected directly to eachother allowing multiple units to move in unison with each other,eliminating independent movement of each unit as it floats on the water.In addition, according to various exemplary embodiments, the hardwareused for connecting the dock units is enclosed within the floatationchamber so as to eliminate exposure to water and elements.

In other exemplary embodiments, the invention further includes a modularfloating dock system. In these embodiments, the modular floating docksystem includes two or more modular floating dock units, each unitincluding a molded floatation shell, a foam filled decking piece, and awater-tight retainer ring interposed between the floatation shell andthe decking piece. In these exemplary embodiments, the assembled dockunits creates a water-tight floatation chamber therein. In variousexemplary embodiments, support members are located inside the floatationchamber, thereby removing them from exposure to the water and theenvironment. In some exemplary embodiments, the two or more floatationshells are connected so as to eliminate independent movement between thetwo or more dock units. In these exemplary embodiments, the hardwareconnecting the modular dock units is located inside the floatationchamber, thereby removing it from exposure to the water and theenvironment. In some embodiments, the modular floating dock systemfurther includes a linear boat bumper that surrounds the dock system.

In various other exemplary embodiments, the invention includes a linearboat bumper system suitable for use on an aquatic dock comprising aplurality of hollow molded bumper units the bumper units being optimizedto provide an upper lip, an expansion pocket, a side rail recess and alower lips such that a deck edge and side rail of the aquatic dock areencased in the linear boat bumper unit, the hollow unit havingresilience and providing a cushion for object moored against the linearboat bumper unit, the boat bumper units combinable to allow for variousaquatic dock designs.

In these exemplary embodiments, the floatation shells are molded toinclude support columns disposed therein. In these embodiments, thesupport columns extend from the floor of the floatation shell to aboutthe rim of the floatation shell. In these exemplary embodiments, the rimof the floatation shell and the support columns have flanges moldedtherein dimensioned and configured to accept the support members. Invarious exemplary embodiments, when the dock unit is assembled, thesupport members are securely held in place by the decking unit disposedthereon.

These and other features and advantages of the present invention will beset forth or will become more fully apparent in the description thatfollows, the drawings and in the appended claims. The features andadvantages may be realized and obtained by means of the elements andcombinations particularly pointed out in the appended claims.Furthermore, the features and advantages of the invention may be learnedby the practice of the invention or will be apparent from thedescription, as set forth hereinafter.

BRIEF DESCRIPTION OF THE FIGURES

Various exemplary embodiments of the compositions and methods accordingto the invention will be described in detail, with reference to thefollowing figures wherein:

FIG. 1 is a perspective view of a completed dock unit according to oneexemplary embodiment of the invention.

FIG. 2 is a top-plan, perspective view of the interior of the moldedfloatation shell according to the embodiment of the inventionillustrated in FIG. 1.

FIG. 3 is a partial top-plan, perspective view of the interior of thefloatation shell illustrating the support columns holding the supportmembers.

FIG. 4 is a perspective view of the bottom of molded flotation shellaccording to the embodiment of the invention shown in FIG. 1.

FIG. 5 is a bottom-plan, perspective view of an assembled dock unitaccording to the embodiment illustrated in FIG. 1

FIG. 6 is a top-plan, perspective view of two molded floatation shellsnested for storage or shipment according to the exemplary embodimentillustrated in FIG. 1.

FIG. 7 is a top-plan perspective view of a foam filled decking pieceaccording to the exemplary embodiment of the invention illustrated inFIG. 1.

FIG. 8 is a perspective view of a water-tight retainer ring according toone exemplary embodiment of the invention.

FIG. 9 is a perspective view of the bottom of a foam filled deck pieceshown in FIG. 5, according to the exemplary embodiment shown in FIG. 1.

FIG. 10 is a perspective view of a second exemplary embodiment of a foamfilled decking piece according to the exemplary embodiment of theinvention illustrated in FIG. 1.

FIG. 11 is a side-plan, perspective view of multiple eight-foot sectionsof molded floatation shells nested in each other according to oneexemplary embodiment of the invention. The flotation shells can betransported stacked and stored stacked, greatly increasing the economyfor transportation and storage.

FIG. 12 is a diagram showing a side rail in cross-section according toone exemplary embodiment of the invention.

FIG. 13 is a diagram of the exemplary embodiment of the side railillustrated in FIG. 12 but in position on a fully assembled dock unit.

FIG. 14 is a schematic, top plan view of two dock units abutted forconnecting together. This view shows the outside of the floatationshells molded with buttresses to result in open channels for waterdrainage.

FIG. 15 is a diagram showing one embodiment of two dock units connected.

FIG. 16 is a drawing illustrating a second exemplary embodiment ofconnecting to dock units according to the invention. Illustrated are ajoint connector edge piece and internal brackets for connecting two dockunits of the invention.

FIG. 17 is a drawing illustrating an enlarged view of the end bracketused for connecting two dock units according to the exemplary embodimentof the invention illustrated in FIG. 16.

FIG. 18 is a schematic partial, top-plan view illustrating theapplication of the water-tight retainer ring to the floatation shellprior to the installation of the one-step foam decking piece. Insetshows the water-tight retainer applied to the entire floatation shellrim.

FIG. 19 is a schematic diagram illustrating three exemplary embodimentsof the floatation shell according to the invention. Illustrated arethree sizes of shell 4′×2′×12′, 8′×2′×12′ and 6′×2′×12′, each with adifferent configuration of support columns as is desired to support thedecking piece. In some embodiments, the floatation shells have differentsize support columns as may be desired. For example, the 8′ shell has amiddle row of support columns that have a larger footprint than theouter rows.

FIG. 20 is a perspective view of one exemplary embodiment of arotational mold useful in fabricating the floatation shells according tothe present invention. The embodiment shown represents a “2 UP” mold,fabricating two shells at the same time.

FIG. 21 is a photograph showing a piece of one-step foam such as thatused for fabricating the water-tight retainer ring and the deckingpieces according to one exemplary embodiment of the invention.Illustrated is the hard outer skin with an interior foam core.

FIG. 22 is a schematic drawing illustrating the use of corner deck unitsto provide a boat slip according to one exemplary embodiment of theinvention.

FIG. 23 is a drawing illustrating one embodiment of an inner 90° cornersplice unit for a side rail boat bumper system according to oneexemplary embodiment of the invention.

FIG. 24 is a drawing illustrating one embodiment of an outer 90° orcorner splice unit for a side rail boat bumper system according to oneexemplary embodiment of the invention.

FIG. 25 is a drawing illustrating one embodiment of a pipe brackethousing splice unit for a side rail boat bumper system according to oneexemplary embodiment of the invention.

FIG. 26 is a drawing illustrating one embodiment of a power pedestalsplice unit for a side rail boat bumper system according to oneexemplary embodiment of the invention.

FIG. 27 is a drawing illustrating an outside piling bracket and jointconnector for the modular dock system according to one exemplaryembodiment of the invention.

FIG. 28 is a drawing illustrating an anchor chain attachment bracketaccording to one exemplary embodiment of the invention.

FIG. 29 is a drawing illustrating a tie off cleat bracket according toone exemplary embodiment of the invention.

FIG. 30 is large piling bracket according to one exemplary embodiment ofthe invention.

FIG. 31 is a drawing illustrating a boat slip corner deck unit accordingto one exemplary embodiment of the invention.

FIG. 32 is a drawing illustrating an accessory floatation unit accordingto one exemplary embodiment of the invention. In this embodiment theaccessory flotation unit has a single fixation tab.

FIG. 33 is a drawing illustrating a second embodiment of an accessoryfloatation unit according to the invention. In this embodiment theaccessory floatation unit is larger and includes two fixation tabs.

FIG. 34 illustrates another exemplary embodiment of the floating dockaccording to the invention showing the use of auxiliary deck brackets toreinforce the dock unit.

FIG. 35 illustrates the embodiment of the invention shown in FIG. 34 butwith the water-tight ring in place.

FIG. 36 illustrates the exemplary embodiment illustrated in FIGS. 34 and35 with the deck installed.

FIG. 37 is a rendering of a dock assembly system. In this embodiment,the middle dock assembly units are 24′×8′ while the perpendicular unitsare 24′×4′.

FIG. 38 is a cross section through a completed dock unit.

FIGS. 39A-H show various perspectives of a 24 ft side rail portion ofone embodiment of a linear boat bumper according to the invention. FIG.39A is a perspective rendering of the side rail. FIG. 39B is a bottomplan view of a portion of the side rail. FIG. 39C is a side plan view ofthe side rail. FIG. 39D is a cross section of the side rail taken alongline B-B of the view shown in FIG. 39C. FIG. 39E is a top-plan view of aportion of the side rail. FIG. 39F is a back-plan view of a portion ofthe side rail. FIG. 39G is a cross section of the side rail taken alongline A-A of FIG. 39F. FIG. 39H is a right end view of the side rail.

FIGS. 40A-40G illustrate one embodiment of a 45° reducing splice bracketcover in one embodiment of a linear boat bumper according to theinvention. 40A is a perspective, top-plan view of the cover. 40B is aperspective bottom-plan view of the cover. FIG. 40C is a schematicdiagram of a perspective top-plan view of the cover. FIG. 40D is aschematic diagram of a bottom-plan view of the cover. FIG. 40E is a sideplan view of the cover. FIG. 40F is a cross section of the cover takenalong line C-C of FIG. 40. FIG. 40G is a cross section of the covertaken along line A-A of FIG. 40E.

FIGS. 41A-41E illustrate a cleat bracket cover according to oneembodiment of a linear boat bumper according to the invention. FIG. 41Ais a perspective top-plan view of the cleat bracket cover according toone embodiment of the invention. FIG. 41B is a side-plan view of thisembodiment. FIG. 41C is a cross section through lines A-A shown in FIG.41B. FIG. 41D is a top-plan view of the cleat bracket. FIG. 41E is across section of the cleat bracket taken along lines B-B of FIG. 41D.

FIGS. 42A-42G illustrate one embodiment of a 45° inside corner bumperaccording to one embodiment of a linear boat bumper system according tothe invention. FIG. 42A is a perspective, top-plan outside view of thebumper part. FIG. 42B is a perspective bottom-plan view of the bumperpart according to the invention. FIG. 42C is a schematic side-plan viewof the bumper part. FIG. 42D is a cross section taken along lines A-A ofFIG. 42C. FIG. 42E is a cross section of the bumper part taken alonglines C-C of FIG. 42C. FIG. 42F is a perspective end-plan view of thebumper part and FIG. 42G is a cross section through the bumper alonglines B-B shown in FIG. 42F.

FIGS. 43A-43G illustrate one embodiment of a 90° outside corner bumperunit according to one embodiment of a linear boat bumper systemaccording to the invention. FIG. 43A is a perspective top-plan view ofthe bumper piece. FIG. 43B is a right side view while FIG. 43C is across section view taken through line A-A of FIG. 43B. FIG. 43D is aleft side view and FIG. 43E is a cross section of FIG. 43D taken alonglines B-B. FIG. 43F is a bottom plan view of the bumper part and FIG.43G is a top plan view of the bumper

FIGS. 44A-44D illustrate one embodiment of a power pedestal bracketcover according to one embodiment of a linear boat bumper systemaccording to the invention. FIG. 44A is a perspective top-plan view.FIG. 44B is a perspective bottom-plan view. FIG. 44C is a schematicdiagram of a side plan view while FIG. 44D is a cross section of thebracket cover taken along lines A-A of FIG. 44C.

FIGS. 45A-45B illustrate one embodiment of a small piling bracket coveraccording to one embodiment of a linear boat bumper system according tothe invention. FIG. 45A is a perspective top-plan view while FIG. 45B isa perspective bottom-plan view of the small piling bracket cover.

FIGS. 46A-46B illustrate one embodiment of a splice bracket coveraccording to one embodiment of a linear boat bumper system according tothe invention. FIG. 46A is a perspective top-plan view of the bracketcover and FIG. 46B is a perspective, inside bottom-plan view.

FIGS. 47A-47E illustrates utility anchor/drag rail bracket coveraccording to one embodiment of the invention. FIG. 47A is a top-planperspective view. FIG. 47B is a side-plan view. FIG. 47C is a crosssection view taken along line A-A of FIG. 47B. FIG. 47D is a top-planview and FIG. 47E is a cross section of FIG. 47D taken through line B-B.

FIGS. 48A-48B illustrate one embodiment of a triangle corner deck coverwith no hole. FIG. 48A is a perspective top-plan view. FIG. 48B is aperspective bottom-plan view.

FIGS. 49A-49B illustrate one embodiment of a triangle corner deck coverwith a hole. FIG. 49A is a perspective top-plan.

FIG. 50 is an exploded view of one exemplary embodiment of a frameassembly of support members according to the invention.

FIG. 51 is a perspective view of the exemplary embodiment of the supportmembers illustrated in FIG. 50 pinned to provide a frame assemblyaccording to the invention.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

A modular dock unit and system for making large modular dock networks isdisclosed. The system includes a rotational molded floatation shell, arotational molded decking piece and a rotational molded water-tightretainer ring. The floatation shell has column supports molded thereinsuitable for holding support members. In use, support frame members areplaced in flanges molded into the support columns and the floatationshell rim. The water-tight retainer is placed and attached on the sidesupport members and the decking piece is opposed to the water-tightretainer. Mounting aids such as tongue and groove members are molded inopposing pieces of floatation shell, retainer and deck and secured wherenecessary. The dock unit also includes side rails that mate with thedock units also by molded mounting aids. When assembled, the dock unitcomprises a water-tight flotation cavity protecting the internalcomponents and providing buoyancy to the dock unit.

Therefore, in various exemplary embodiments, the invention disclosedherein provides a molded floatation shell including a bottom and sidewalls, a molded foam decking piece designed and configured to fit overthe top of the floatation shell, and a molded water-tight retainer ringdesigned and configured to fit between the decking piece and thefloatation shell. Upon securing of decking piece to the floatationshell, with the retainer ring interposed therebetween, a water-tightfloatation chamber is created. Each assembled unit thereby provides afloating dock unit.

In some exemplary embodiments, the molded floatation shell, the foamdecking piece and the water-tight retainer ring are made by rotationalmolding. In still other exemplary embodiments, the floatation shell isfurther molded to include support columns in the interior of thefloatation shell ascending from the bottom of the shell to the upper rimof the shell. In various exemplary embodiments, the columns are hollowin the interior. In these exemplary embodiments, the shells arestackable, nesting within each other such that each additional shellincreases the height of the stack by little more than the thickness ofthe shell. In various exemplary embodiments, the floatation shell isbetween about 3/16 to about ¼ inches in thickness. However, those ofskill in the art will appreciate that the floatation shell can be anythickness desirable that is amendable either a single wall or a doublewall part which is foam filled utilizing a foam molding fabrication.Further, when nested together, the stacks of floatation shells areextremely space efficient and are easy to transport. Those of skill inthe art will recognize that the floatation shell, the decking piece andthe water-tight retainer ring can be made by any suitable method,including conventional molding or milling. In some exemplaryembodiments, the water-tight retainer ring and the decking piece aremade using “one-step” rotational molded technology. In other exemplaryembodiments, the molded dock unit components are made using two-stepmolding technology.

Further, while in some exemplary embodiments, the floating dock unitsare rectangular, and have dimensions of approximately 24′×4′×2′;24′×6′×2′; and 24′×8′×2′; and 12′×24′×2′, those of skill in the art willrecognize that one advantage of molding the units is that they can beany size required such as circular, hexagonal, trapezoidal, etc.Therefore, there is very little limitation imposed upon the size andshape of the units disclosed according to the instant invention.

In various exemplary embodiments, the floatation shell is molded toinclude flanges disposed within side walls of the shell and the supportcolumns. The flanges are designed and configured to accept supportmembers such that when the dock unit is assembled, the support membersare securely held in place in the watertight floatation chamber by thefoam decking piece to which the support members also provide support. Instill various other exemplary embodiments, the dock unit includes amolded side rail dimensioned and configured to intercalate between thedecking piece and the water-tight ring such that when the dock unit isassembled the side rail is securely held in place. In addition, invarious exemplary embodiments, the molded side rail is hollow and allowsflexing, thereby eliminating the need for accessories such as boatbumpers.

In some exemplary embodiments, the invention also includes methods forconnecting the modular dock units such that the dock units can besecurely attached to each other in any desired configuration. In theseexemplary embodiments, the dock units are connected directly to eachother allowing multiple units to move in unison with each othereliminating independent movement of each unit as it floats on the water.In addition, according to various exemplary embodiments, the hardwareused for connecting the dock units is enclosed within the floatationchamber so as to eliminate exposure to water and elements.

In other exemplary embodiments, the invention further includes a modularfloating dock system. In these embodiments, the modular floating docksystem includes two or more modular floating dock units, each unitincluding a molded floatation shell, a foam decking piece, and awater-tight retainer ring interposed between the floatation shell andthe decking piece. In these exemplary embodiments, the assembled dockunits create a water-tight floatation chamber therein. In variousexemplary embodiments, support members are located inside the flotationchamber, thereby removing them from exposure to the water and theenvironment. In some exemplary embodiments, the two or more floatationshells are connected so as to eliminate independent movement between thetwo or more dock units. In these exemplary embodiments, the hardwareconnecting the modular dock units is located inside the floatationchamber, thereby removing it from exposure to the water and theenvironment.

In these exemplary embodiments, the floatation shells are molded toinclude support columns disposed therein. In these embodiments, thesupport columns extend from the floor of the floatation shell to aboutthe rim of the floatation shell. In these exemplary embodiments, the rimof the floatation shell and the support columns have flanges moldedtherein dimensioned and configured to accept the support members. Invarious exemplary embodiments, when the dock unit is assembled, thesupport members are securely held in place by the decking unit disposedthereon.

In various other exemplary embodiments, the invention includes a linearboat bumper system suitable for use on an aquatic dock comprising aplurality of hollow molded bumper units the bumper units being optimizedto provide an upper lip, an expansion pocket, a side rail recess and alower lips such that a deck edge and side rail of the aquatic dock areencased in the linear boat bumper unit, the hollow unit havingresilience and providing a cushion for object moored against the linearboat bumper unit, the boat bumper units combinable to allow for variousaquatic dock designs.

Referring now to FIG. 1, a top-plan, perspective view of one dock unit10 according to one exemplary embodiment of the invention isillustrated. As shown, the dock unit 10 includes a molded floatationshell 100, a foam filled decking piece 200 and a water-tight retainerinterposed between the two.

FIG. 2 illustrates the interior of the floatation shell 100. As shown,the floatation shell 100 is of unitary construction comprising a bottomand in the rectangular embodiment illustrated, four side walls. In someexemplary embodiments, the floatation shell is made by rotationalmolding. While the embodiments shown illustrates the floatation shellhaving a rectangular size, those of skill in the art will recognize thatthe floatation shell can have any size desired limited only by thelimits of rotational molding construction. As shown in FIG. 2, thefloatation shell has four side walls 124 with each side molded toinclude a lip or rim 126 thereon dimensioned and configured to sidesupport member 130. The floatation shell 100 also includes supportcolumns 102 regularly spaced therein and about equal in height to theside walls. In various exemplary embodiments, the support columnsfurther include flanges 104 projecting upward from the end andconfigured to create grooves 106 or pockets therein dimensioned andconfigured to accept longitudinal 132 and transverse 134 supportmembers. Therefore, those of skill in the art will appreciate that thedepth of the floatation shell can be any depth that is great enough toaccommodate the support column and the support members. In variousexemplary embodiments, the floatation shell has a depth of approximatelytwo feet. However, as will become apparent, the depth can be as small asabout one foot and can be any greater depth as desired.

As illustrated in FIGS. 2 and 3, the floatation shells 100 can be moldedto include regularly spaced support columns 102 as desired. Thus, invarious exemplary embodiments, larger floatation shells will have moresupport columns while smaller floatation shells would have fewer supportcolumns. As discussed above, the shells 100 and columns 102 aredimensioned and configured to accept support members 128 including sidesupport members 130, longitudinal support members 132 and transversesupport members 132. In various exemplary embodiments, side walls 124and top rims 126 are adapted to accept side support members 130 (notshown) that fit into the side walls 124 of the floatation shells 100. Invarious exemplary embodiments, flanges 142 are molded into the sidewalls 124 of the floatation shells 100 to facilitate securing the sidesupport members 130 to the floatation shell as shown in FIG. 3.

FIG. 4 is a perspective view of the underside 120 of a floatation shell100 according to the exemplary embodiment of the invention shown inFIGS. 1-3. FIG. 4 illustrates the 3-dimensional nature of the floatationshell 100 and hollow support columns 122 disposed therein allowing thestacking or nesting of multiple floatation shells 100 for storage orshipment. Also shown, the interior of the support columns 122 comprisepockets for accepting a drag rail tongue securing the drag rail (notshown) to the underside 120 of the floatation shell 100. A supportbracket 144 for the drag rail is also illustrated.

One advantage of providing hollow support columns 102 is illustrateddiagrammatically in FIG. 11, showing that nesting stacked shells resultsin as little as about, approximately, a 4″ to 16″ increase in the sizeof the stack for each additional shell. Those of skill in the art willappreciate that the savings of space provided by nesting multiplefloatation shells greatly reduces the cost of shipping compared tonon-nesting units which require multiple trucks to transport the samenumber of floatation shells as when nested.

FIG. 5 is a bottom perspective view of a partially assembled dock unit10. In this embodiment of the invention, drag rails 136 are included.Those of skill in the art will appreciate that drag rails 136 are onlynecessary on those dock units that contact the littoral bottom such asthe first in a series of units along a lake, a river or an ocean. Thedrag rails 136 then accept the stress and deterioration resulting fromconstant impact and friction with the littoral bottom, thereby rescuingthe floatation shell 100 from constant wear and tear. Further, accordingto the exemplary embodiment illustrated, the drag rails are easilyaffixed to the floatation shell bottom and can be easily removed and/orreplaced as needed. Therefore, in various exemplary embodiments, thefloatation shell can be molded such that the underside of the supportcolumns 102 comprise a slot 138 dimensioned and configured to accept atongue 140 on the drag rail 136 as illustrated in FIGS. 4 and 5. Forease of mounting, the drag rails need only be attached to the dock unitby use of a single drag rail support bracket 144 at the end of each dragrail 136. The drag rail support bracket 144 is bolted into the drag rail136 at one end and at the other end is bolted through the floatationshell 100 into the side support member 130. Because the drag railtongues 140 mate with the slots 138 molded into the bottom of theflotation shell 100, the drag rail 136 is easily yet securely affixed tothe bottom of the flotation shell. Of course, those of skill in the artwill appreciate that the drag rail is further affixed to the shell byuse of any other necessary hardware such as bolts, nuts, screws, etc.Further, because only one mold is necessary to fabricate each size offloatation shell desired features, such as slots 138, are molded intoevery shell, each drag rail is replaceable with similar drag rails forall sizes of dock units 10.

FIG. 6 is an illustration showing two floatation shells nested together.As discussed above, the fabrication of identical floatation shells bymolding technology results in 3-dimensional, stackable floatation shellswith the addition of each additional shell increasing the height of thestack by only approximately eight inches, e.g., the thickness of theshell. This feature greatly increases the economy of shipping andstoring dock units and further increases the ease of assembly. Alsoillustrated in FIG. 6 are transverse support members 134 and sidesupport members 130.

FIG. 7 illustrates a foam filled decking piece 200 according to oneexemplary embodiment of the invention. As illustrated in FIG. 7, eachdecking piece 200 is unitary and molded to be matable to the floatationshell 100. Interposed between the floatation shell, the side supportmember 130 and the decking is a water-tight retainer ring 300. Alsoillustrated is a side rail 310 configured to clad all deck units asdesired. In various exemplary embodiments, the water-tight retainer 300is fabricated from polymers such as LLDPE resins (linear low-densitypolyethylene). Any type of resin used in conventional molding may beutilized. Examples of other types of resins useful in the method of thisinvention include polycarbonates, nylons, polyvinylchlorides, andpolyesters. Additional useful resins include ABS, acetals, acrylics,cellulosics, epoxies, fluorocarbons, phenolics, polystyrenes,polyurethanes, SAN polymers, and silicone polymers EVA copolymers andEBA. The water-tight retainer can be fabricated using moldabletechnology and is fabricated in any size necessary to conform to thedimensions of the floatation shell 100 and decking piece 200. FIG. 8provides a schematic diagram of one exemplary embodiment of awater-tight retainer ring 300.

FIG. 9 is a perspective view of the underside of the decking piece 200.In this view, the side rails 310 are attached to the side of the deckingpiece on the longitudinal sides while the transverse sides of thedecking piece have not had the side rails 310 yet attached. On thetransverse or ends of the decking piece the side support members arestill visible showing attachment of the drag rail supports 134. Severaltransverse support members 134 are also illustrated.

FIG. 10 illustrates an alternative embodiment of a one-piece moldeddecking piece 200. Those of skill in the art will appreciate thatbecause the decking pieces are fabricated by the rotational moldingprocess, any desired pattern for the decking can be achieved. Thus, thepatterns illustrated in FIGS. 1, and 10 should not be consideredlimiting in any way.

FIGS. 12 and 13 illustrate the molded side rails 310. FIG. 12illustrates the side rail 310 in a cross-sectional view beforeinstallation on the dock unit 10. As illustrated, the side rail isroughly ‘L’ shaped having a rounded contact side 316 and a bottomtransverse side 318 with a locking ‘V’ or groove 320. Also illustratedis a locking tab 322 at the top of the contact side 316. FIG. 13 is across sectional view of the side rail 310 affixed to an assembled dockunit 10. As shown in FIG. 13, in one exemplary embodiment the rim 126 ofthe flotation shell 100 is molded to project from the side wall 124. Theunderside of the rim 126 includes a locking mechanism, such as a tongue150 designed and configured to mate with the locking ‘V’ or groove 320molded into the side rail 310. Further, as shown in FIG. 13, the sidesupport members 130 fit within the top rim 126 of the flotation shell100.

The water-tight retainer ring 300 is configured to overlay the supportmember 130 and includes an overhanging flange 324 that projects over theside of the rim 126 covering the junction of the floatation shell rim126 and the side support member 130. In addition, the retainer ring 300also includes one or more upwardly projecting tongues 326 and aredesigned and configured to matingly engage corresponding grooves 212 onthe underside of the foam deck 200. The side rail locking tab 322creates a notch 336 in which the retainer ring overhang 324 sits whilethe locking tab projects above the retainer ring 300 and abuts the sideof the one-step deck 200. In various exemplary embodiments, the siderail locking tab 322 is then secured to the deck piece 200 using anysuitable method. In the exemplary embodiment illustrated in FIG. 13, ascrew is inserted into a locking nut in the decking piece through ahardware opening molded into the side rail 310. In addition, thewater-tight retainer ring 300 is affixed to the side support member 130by multiple screws through spaced, recessed lag bolt holes molded intothe retainer ring as illustrated. However, those of skill in the artwill recognize that any usable method of maintaining the water-tightretainer in position is contemplated such as, for example, an adhesive.

Those of skill in the art will appreciate that the support members 128(e.g., side support members 130, longitudinal support members 132 andtransverse support member 134) can be any size that is necessary toaccommodate the support columns 102 including the flanges 104 andgrooves 106 formed thereby to provide support for the decking pieces100. Therefore, in various exemplary embodiments, the support memberscan be 4″×6″, 6″×6″, 6″×8″ or any other convenient size. Advantageously,when necessary, hardware such as a washer, lock washer and nut fit intothe locking tongue or ‘V’ groove 150 of the floatation shell so as notto interfere with the seal of the water-tight ring 300 interposedbetween the support member 130 and the deck piece 200. FIG. 30illustrates a large piling bracket 370 for use with one exemplaryembodiment of a corner deck piece 372 as shown in FIG. 31. Also shown isa trim ring 374 usable with the piling bracket 372.

FIG. 14 is a schematic top-plan view of two dock units abutted. Asillustrated, in some exemplary embodiments, the floatation shells 100are designed to have protruding buttresses 152 molded therein such thatwhen fixed together in multiple units, the opposing buttresses createopenings between them allowing water to drain from the decking FIG. 15is a close-up view illustrating one exemplary embodiment of connectingadjoining dock units. As shown in some exemplary embodiments, when theunits 10 are to be connected, the side rail is not affixed to theabutting sides. A spacer 340, such as a high density polyethylene (HDPE)panel is then interposed between the two units below the water-tightretainer ring overhang 324. As illustrated, the spacer 340 runs thelength of the side of the decking units being abutted, is the width oftwo retaining ring overhangs and is the height of the portion of the rimnot covered by the retaining ring overhang. An upside down 1′ typebracket 330 is then mounted on the inside of the rim 126 such that theupper portion of the retainer ring is affixed to the bracket such as byscrews, bolts are then placed through the bracket and the spacer,holding the two units together. However, those of skill in the art willappreciate that in other exemplary embodiments, a side support member130 would be placed in the overhang as illustrated in FIG. 13 and, withthe HDPE panel 340 interposed between the two dock units, the unitswould be bolted together through the support members 130.

FIGS. 16 and 17 illustrate a second exemplary embodiment of connectingtwo or more dock units. FIG. 16 illustrates side joint connectors 332which span the outside of the floatation shells along the joint and arefastened through the floatation shell into the support members 130 whileFIG. 17 illustrates the internal end brackets 328. As illustrated inFIG. 17, one end bracket is fastened to side support member 130 insideone opposing floatation shell and fastened to the longitudinal supportmembers 132 while a second opposing bracket is juxtaposed in theopposite dock unit such that the end bracket 328 are fastened to eachother through the shell 100 joining the two dock units 10 together. Inthe exemplary embodiment illustrated in FIGS. 16 and 17, a side supportmember 130 on the abutted end is not used and the brackets 328 arefastened to the longitudinal support member 132.

FIG. 18 is a partial top-plan view of the retaining ring 300. As shown,the retaining ring sits on top of the side support members 130. Thelocking tongues 326 project upward and the side rails 310 have beenaffixed to the floatation shell 100. In some exemplary embodiments,screw holes may be molded into the retainer ring 300 upon fabrication tofacilitate attachment to the support member 130. The inset shows oneembodiment of a floatation shell 100 with the water-tight retainer 300in place awaiting positioning of the deck piece 200.

FIG. 19 is a schematic top-plan view of three exemplary embodiments offloatation shells according to the invention. The embodimentsillustrated show a 4′×24′ floatation shell with a single row of supportcolumns molded therein; an 8′×24′ floatation shell with three rows ofsupport columns molded therein and a 6′×24′ floatation shell with tworows of support columns molded therein. Not illustrated are 12′×24′shells having either three or four rows of support columns 102. Further,it should be noted that the embodiment illustrated of the 8′×24′floatation shell the middle row of columns is offset from the outer rowsthereby providing greater support for the support members and theoverlaying decking. The bottom of the figure shows that the size of thesupport columns can be optimized for each size floatation shell used.For example, the 4′ shell having only a single row of support columnsmay have a rectangular frustoconical shape with the supports 110 in thesmaller shells generally having a larger base than those in the largerunits. As illustrated, in some exemplary embodiments, the 4′ shell has asingle row of support columns 102 that are 12″×12″ along the base whilethe 8′ shell having 3 rows of columns 102 are 8″×8″ at the base. Itshould be noted that while in some exemplary embodiments the shell is24″ deep the height of the support columns in each case is 18″ with theheight of the top rim of the floatation shell being approximately sixinches. The height of the support members is 6 inches, allowing theframe support members to be completely enclosed and protected in theassembled deck unit when foam deck 200 is in place. As will beappreciated, when the floatation shells are 4′×24′, 6′×24′, 8′×24′ and12′×24′ the size of the retainer ring is also 4′, 6′, 8′ and 12′×24′.Further, while the retainer ring 300 can be any thickness necessary toseal the decking onto the shell, in some exemplary embodiments, theretainer ring is three inches thick.

Further, those of skill in the art will appreciate that while thesupport members 130, 132, 134 can be any robust linear material, in someexemplary embodiments the support members are beams such as, forexample, wood, including Douglas fir, lam beams, steel such asgalvanized steel and composite materials such as fiber reinforcedplastics/polymers (FRP).

For those embodiments utilizing FRP, those of skill in the art willappreciate that many types of FRP can be utilized for support members130, 132 and 134. For example, common types of fibers used in FRPcomposites include, but are not limited to: fiberglass, carbon fibers,aramid fibers boron fibers, basalt fibers, wood fibers, flax fibers andhemp fibers. Similarly many different types of resins can be usedincluding, but not limited to: epoxy, vinyl esters, polyesters,polyurethane, propylene, virgin high density polyethylene (HDPE) andrecycled HDPE. Furthermore, those of skill in the art will appreciatethat particular fibers and particular resins can be used in differentcombinations depending on the characteristics of FRP required. Suchcharacteristics include, but are not limited to strength, resiliency andcost effectiveness. Indeed, in some embodiments according to theinvention, support members 130, 132 and 134 may not all be of the samecomposite but rather various composites as required by the particularenvironmental conditions of the end user. Of course, in otherembodiments, support members 130, 132 and 134 may all be of the samecomposite materials.

In addition, as discussed previously, when each dock unit is assembledthe interior of the floatation shell comprises a water-tight interior.Therefore, none of the interior components, such as beams and hardware,come into contact or are degraded by the atmosphere or water. Inaddition, although the interior is water-tight, air bladders can beadded or removed from the interior compartment thus changing thebuoyancy of the dock unit 10. In addition, while the sealed dock unitprovides inherent buoyancy, those of skill in the art will appreciatethat additional buoyancy can be added to units where needed by insertinga foam billet or an adjustable air bladder into the floatation chamberor by connecting an auxiliary flotation unit such as those shown inFIGS. 32 and 33 (discussed below).

Further, as illustrated in the previous and following figures, a varietyof brackets, connectors and other hardware can be used with the modulardock units according to the invention. Those of skill in the art willappreciate that all hardware contemplated for use may be galvanizedsteel, e-coat steel or stainless steel or similar resistant materialsthat may, in the future, become available. As discussed above, thefloatation shells, decking units and water-tight rings are, in someexemplary embodiments, fabricated using the techniques of rotationsmolding. The advantages of fabricating the units using rotation moldingtechniques include that each unit is exactly the same as all otherunits. Therefore, once the molds have been cast, such as from steel oraluminum, the individual components can be fabricated and shipped to thedestination of installation and the units can be assembled on-sitewithout any further refinement or modification of the individual pieces.

The techniques of rotational molding are well known by those of skill inthe art. Briefly, a model is made of the product. A mold is then madeusing the model of the finished product. Once the mold is made, the moldis filled with beads of plastics such as polyethylene, polycarbonate,polyester, nylon, etc. The mold is heated, by for example, putting it inan oven and melting the plastic material inside. The mold is thenrotated, generally along two axes, causing the melted plastic to comeinto contact with and stick to the walls of the mold. The mold is thenallowed to cool and the molded plastic piece removed from the mold.

While the general concepts of rotational molding provide a backgroundfor the fabrication of the instantly disclosed dock units, these methodscan be optimized to provide more robust docking pieces. For example, thefloatation shells and decking pieces can be fabricated from resins suchas LLDPE resins (linear low-density polyethylene). Any type of resinused in conventional rotational molding may be utilized. Examples ofother types of resins useful in the method of this invention includepolycarbonates, nylons, polyvinylchlorides, and polyesters. Additionaluseful resins include ABS, acetals, acrylics, cellulosics, epoxies,fluorocarbons, phenolics, polystyrenes, polyurethanes, SAN polymers, andsilicone polymers EVA copolymers and EBA. Further, floating dock unitsof the size currently contemplated were not available due to limitationsin size and capacity of rotational machinery needed to rotate molds ofthe current size used.

A schematic diagram of one exemplary embodiment of a mold 440 used forthe fabrication of the floatation shells is provided in FIG. 20. Thisfigure illustrates a “2-up” mold 440 because it comprises a top half anda bottom half each half forming a mold for a complete floatation shell100. It should be appreciated that the foam floatation shells 100 anddecking pieces 200 can be fabricated by any desirable method. Forexample, while in some embodiments “one-step” foam technology is used.In other exemplary embodiments such as, for example, “two-step” foammolding technology is sued. Two-step foam technology uses a “drop box”.In other exemplary embodiments a secondary post molding “foam injection”method is used. Further the fabrication technology can compriserotational molding (“rotomolding”) or conventional molding technologies.

In addition, in various exemplary embodiments, both the decking units200 and the water-tight retainer rings 300, will be fabricated from newrotomolding techniques such as “one-step” foam molding, available fromChroma Corporation Inc, McHenry, Ill. See, for example, U.S. Pat. No.6,833,410 hereby incorporated by reference in its entirety for allpurposes. In the one-step rotational molding technique, a foam productis provided using both resin pellets and resin powder. The processresults in a rotationally molded object that is characterized by a hardouter polyethylene skin and an air-filled expanded foam interior. FIG.21 is a photograph showing a section of a one-step foam piece showingthe outer skin and the inner foam. While the one-step process isrelatively new in the rotational molding field of art, it has, to theinventor's knowledge, not previously been used for applications such asthe instant invention. However, the inventor's realization that theunique properties of one-step foam fabrication could be useful in thefabrication of pieces for the instant invention provides a uniqueproduct with previously unavailable qualities. These qualities include,strength, durability, economy of manufacture, economy of shipment andtransport.

In contrast, in the “two-step” process an initial outer skin is formedand then the inner foam core is added later. For example, PVC pelletsare first added in the mold in a desired “charge weight”, the mold isthen heated and the PVC skin is formed. Drop boxes then open and ameasured “charge weight” of PVC is dropped into the mold that forms afurther layer of PVC inside the previously formed layer. While thesecond charge may not be necessary, the second charge adds to thethickness of the outer PVC layer increasing its strength. The PVC outerlayer is then removed from the mold and a post-foam process is utilizedto pressure fill the cavity with a variety of foam agents which willharden during the cooling process creating additional rigidity andfloatation to the part.

In addition, while the general characteristics of the dock units 10according to the invention have been described above, it should beappreciated that various and supplementary attachments, brackets andhardware pieces are usable and contemplated for use with the inventionso as to provide a complete multi unit dock system 600 (FIG. 37).Therefore, corner deck covers 428 as illustrated in FIG. 22 are usefulin boat slips or when there is a step-down in deck size and arecontemplated for use in one exemplary embodiment of the invention. Inaddition, those of skill in the art will recognize that, when differentsize dock units are connected or when multiple dock units are connectedat right angles, the side rail 310 must follow the perimeter of theconnected dock units. Therefore, 90° inside corner splice units 354 suchas the exemplary embodiment illustrated in FIG. 23 are usable in suchinstances. Similarly, 90° outside corner splice units 356 such as theexemplary embodiments illustrated in FIG. 24 can be used to create anoutside corner.

In addition, the modular nature of the side rail 310 allows the use ofvarious other splice units to safely include other utilities andattachments. For example, FIG. 25 illustrates a side rail splice unit358 that incorporates a pipe bracket housing. In some exemplaryembodiments of this unit, the backside of the unit includes a pocketmolded to fit around a metal piling bracket. FIG. 26 illustrates oneexemplary embodiment of a power pedestal bracket 362. The molded unitcan be marked for cutout to access water and power from the bottom ofcavity. As illustrated the power pedestal bracket 362 mounts to the topof the splice unit and extends over the edge of the deck 200. FIG. 27 isan illustration of one exemplary embodiment of an outside pilingbracket, in this embodiment the bracket is a small piling bracket 364.In this embodiment, the piling bracket also acts as a joint connector.The inset provides a top view of the bracket 364. FIG. 28 is aperspective view of an anchor chain attachment bracket 366. Asillustrated, the bracket fits over the side rail with screw holes tosecurely fasten the bracket to the underlying support member 130. FIG.29 illustrates a “tie off” cleat bracket 368 according to one exemplaryembodiment of the invention. As with the small piling bracket (FIG. 27),the cleat bracket shown in FIG. 29 may also act as a joint connector. Asillustrated, the cleat bracket bolts through the side support member130.

FIGS. 32 and 33 are schematic diagrams illustrating two exemplaryembodiments of auxiliary floatation units 350 for use when greaterbuoyancy is desired for an individual floatation dock unit. Asillustrated, the modular design allows the auxiliary floatation units350 to be deployed easily simply by inserting the tab 352 into theopening of the support column 102 on the bottom of the floatation shell100. Those of skill in the art will appreciate that the auxiliaryfloatation units can be any buoyant apparatus which can mate with thefloatation shell support column 102. As shown in FIGS. 32 and 33, theauxiliary floatation unit 350 may comprise an air-bladder by having airpumped into the cavity using a curved pipe from the deck above.Similarly, when the buoyancy needs to be decreased, the air can bepumped out. Those of skill in the art will recognize that auxiliaryfloatation units such as those disclosed herein can be used at singledock unit in a modular docking system and they can remain in place evenwhen not filled with air, such as, for example during a drought orperiod of low water. However, the units can remain in place ready forcharging if environmental changes require.

FIGS. 34-36 illustrate another exemplary embodiment of the floating dockunit 10 according to the present invention. As illustrated, in FIG. 34,reinforcement brackets 360 can be used to further reinforce theattachment of the support member frame 130 to the floatation shell 100for extra security during use in very rough water if desired. In thisexemplary embodiment, as shown in FIG. 34, reinforcement brackets 360are fastened through the floatation shell 100 into side support framemembers 128. The side support members 130 are located inside thefloatation shell 100 and the brackets 360 are bolted through the side ofthe floatation shell 100 and into the support frame members 128. Thereinforcement brackets 360 can also be fastened (top to bottom) bybolting through the metal bracket 360 from the top down, through theside support member 130 and through the side wall 124 of the floatationshell 100. In this embodiment the connection of the side support member130 to the floatation shell 100 can reinforced along the entireperiphery of the dock unit 10 as needed by brackets 360. The water-tightretainer ring 300 is installed on top of the reinforcement brackets 360as shown in FIG. 35. FIG. 36 shows the foam deck 200 applied to thefloatation shell 100 with the side rails 310 visible.

FIG. 37 illustrates one embodiment of a modular floating dock system 600according to the invention. Illustrated are a plurality of modularfloating dock units 10 connected to each other. In this embodiment, themiddle dock units 12 are larger having a size of approximately 24′×8′while the perpendicular dock units 14 are 24′×4′. Of course those ofskill in the art will appreciate that the dock units can be assembled inthe system to comprise any convenient sizes. As illustrated, each of theunits has a floatation shell 100 and a foam deck 200. Also illustratedare the supporting buttresses 152 of the floatation shell 100. Inaddition, when the floating dock units are assembled into a multipleunit system, corner brackets, such as the large piling bracket 370 canbe used to reinforce the connection between the units as well as providebrackets for pylons to fix the dock system to the littoral floor. Alsoshown is a linear boat bumper system 400 that can be affixed to theperimeter of the dock units 10 to completely surround the perimeter ofthe dock system assembled from a plurality of the units 10.

FIG. 38 is a cross section through a completed dock unit 10. In thisview, the floating shell 100 is shown including support column 102 andthe support column flanges 104 which provide support column groove 106.Also shown are the support frame members 128 comprising side supportmember 130, transverse member 134 and longitudinal support members 132which fit within the flanges 104 of the support columns 102. The siderim 126 of the floatation shells 100 are also illustrated on top ofwhich sits the water-tight ring 300 with the foam deck 200 situated ontop of the water-tight ring 300. A shell reinforcement bracket 360 isvisible below the edge of the dock unit 10. Surrounding the entire unitis a linear boat bumper 400 also visible is a small piling bracket cover422 which covers the small piling bracket (not visible).

FIGS. 39-47 illustrate various embodiments of the linear boat bumper400. FIG. 39H illustrate various embodiments of a 24′ bumper rail 410 ofthe linear boat bumper system 400 according to one embodiment of theinvention. In this embodiment, the straight section 410 is approximately12″ wide thereby approximating the size of the rim 126 of the flotationshell. FIG. 39A is a perspective rendering of the linear bumper rail410. 39B is a bottom plan view of a portion of the linear bumper rail.39C is a side plan view of the bumper rail also shown are lag-bolt holes518 regularly spaced along the bumper 410 for attachment directly intothe framing member 130 of dock unit 10. 39D is a cross section of theside rail taken along line B-B of the view shown in FIG. 39C. Shown inthis view, the various members of the bumper system 400 generally havean upper lip 510, a bottom lip and a side rail recess and an expansionpocket 516. In use, the upper lip 510 extends over the top of the foamdeck 200. The deck 200 fits into the expansion pocket and the remainderof the side rail 310 fits within the recess 514 defined by the bottomlip 512. The bottom lip 512 extends under the side rail 310 such thatthe entire side rail portion of the dock unit is protected by thebumper. This arrangement is illustrated in FIG. 38. Further, theexpansion pocket allows the deck 200 to expand and contract depending onthe temperature of the environment without disturbing the bumperalignment along the dock unit.

In the embodiment illustrated, the linear boat bumper system 400 can bemade of any moldable polymer. Examples of such polymers include LLDPEresins (linear low-density polyethylene). However, any type of resinused in conventional molding may be utilized. Examples of other types ofresins useful in the method of this invention include polycarbonates,nylons, polyvinylchlorides, and polyesters. Additional useful resinsinclude ABS, acetals, acrylics, cellulosics, epoxies, fluorocarbons,phenolics, polystyrenes, polyurethanes, SAN polymers, and siliconepolymers EVA copolymers and EBA. When molded the pieces of the linearbumper system are hollow they provide resilience and cushioning forboats moored to the dock units 10 as well as providing a sacrificialunit to protect other portions of the dock unit 10. In addition, it willbe appreciated that the linear bumper rail can be cut to any lengthnecessary to provide an exact fit for the linear bumper rail 400 whencustomized to any type of dock unit.

FIG. 39E is a top-plan view of a portion of the linear bumper rail. FIG.39F is a side-plan view of a portion of the side bumper from the back.FIG. 39G is a cross section of the linear rail taken along line A-A ofFIG. 39F. FIG. 39H is a right end view of the side rail 410. Both FIGS.39G and H illustrate that, in cross section, the linear bumper sectionsinclude an upper lip 510, an expansion pocket 516, a side rail recess514 and a lower lip 512 to surround and protect the side rails 310 ofthe floatation shells.

FIGS. 40A-40H illustrate one embodiment of a 45° reducing splice bracketcover 412 according to the invention. 40A is a perspective, top-planview of the cover. 40B is a perspective bottom-plan view of the cover.FIG. 40C is a schematic diagram of a perspective top-plan view of thecover. FIG. 40D is a schematic diagram of a bottom-plan view of thecover. FIG. 40E is a side plan view of the cover. FIG. 40F is a crosssection of the cover taken along line C-C of FIG. 40E. FIG. 40G is across section of the cover taken along line A-A of FIG. 40E. Both FIGS.40F and 40G illustrate that each of the pieces includes a top lip 510,an expansion pocket 516, a side rail recess 514 and a lower lip 512.

FIGS. 41A-41G illustrate a cleat bracket cover 414 according to oneembodiment of the invention. The cleat bracket cover 414 is configuredto cover a cleat bracket 368, such as illustrated in FIG. 29. FIG. 41Ais a perspective top-plan view of the cleat bracket cover according toone embodiment of the invention. FIG. 41B is a side-plan view of thisembodiment. FIG. 41C is a cross section through lines A-A shown in FIG.41B. FIG. 41D is a top-plan view of the cleat bracket. FIG. 41E is across section of the cleat bracket taken along lines B-B of FIG. 41D.Both FIGS. 41C and 41E illustrate that, in cross section, the cleatbracket cover 414 includes the upper lip 510, expansion pocket 516, aside rail recess 514 and a lower lip 512.

FIGS. 42A-G illustrate one embodiment of a 45° inside corner bumper 416unit according to one embodiment of the invention. FIG. 42A is aperspective, top-plan outside view of the bumper unit. FIG. 42B is aperspective bottom-plan view of the bumper part according to theinvention. FIG. 42C is a schematic side-plan view of the bumper part.FIG. 42D is a cross section taken along lines A-A of FIG. 42C. FIG. 42Eis a cross section of the bumper part taken along lines C-C of FIG. 42C.FIG. 42F is a perspective end-plan view of the bumper part and FIG. 42Gis a cross section through the bumper along lines B-B shown in FIG. 42F.As illustrated in FIGS. 42D and F the inside corner bumper 416 furtherincludes upper lip 510, expansion pocket 516, a side rail recess 514 anda lower lip 512 also illustrated is lag-bolt hole 518 for attachment ofthe bumper unit 416 to the frame member 130 of the floatation shell.

FIGS. 43A-G illustrate one embodiment of a 90° outside corner bumperpiece 418 according to the invention. FIG. 43A is a perspective top-planview of the bumper piece 418. FIG. 43B is a right schematic diagram ofthe bumper piece 418 while FIG. 43C is a cross section view takenthrough line A-A of FIG. 43B. FIG. 43D is a left side view and FIG. 43Eis a cross section of FIG. 43D taken along lines B-B. FIG. 43F is abottom plan view of the bumper part and FIG. 43G is a top plan view ofthe bumper. As illustrated in FIGS. 43C and E, the bumper piece 418includes upper lip 510, expansion pocket 516, a side rail recess 514 anda lower lip 512 also illustrated is lag-bolt hole 518 for attachment ofthe bumper unit 418 to the frame member 130 of the floatation shell.

FIGS. 44A-44D illustrate one embodiment of a power pedestal bracketcover 420 according to the invention. The bracket cover 420 isconfigured to cover a power pedestal bracket such as, for example 362illustrated in FIG. 26. FIG. 44A is a perspective top-plan view of cover420. FIG. 44B is a perspective bottom-plan view of cover 420. FIG. 44Cis a schematic diagram of a side plan view while FIG. 44D is a crosssection of the bracket cover taken along lines A-A of FIG. 44C. As canbe seen from FIG. 44A, because the bracket cover surrounds the powerpedestal bracket, there is no upper lip 510. However, as seen in FIG.44D, the bracket cover 420 includes expansion pocket 516, a side railrecess 514 and a lower lip 512 also illustrated is lag-bolt hole 518 forattachment of the bumper unit 416 to the frame member 130 of thefloatation shell.

FIGS. 45A-45B illustrate one embodiment of a small piling bracket cover422 according to the invention. Bracket cover 422 is suitable for usewith small piling bracket 364 illustrated in FIG. 27. FIG. 45A is aperspective, top-plan view. FIG. 45B is a perspective bottom-plan viewof the small piling bracket cover 422. FIGS. 45A and B illustrate theupper lip 510, expansion pocket 516, side rail recess 514 and lower lip512 of the linear boat bumper system 400.

FIGS. 46A and 46B illustrate one embodiment of a splice bracket cover424 according to the invention. FIG. 46A is a perspective top-plan viewof the bracket cover and FIG. 46B is a perspective, inside bottom-planview. FIGS. 46A and 46B illustrate the upper lip 510, expansion pocket516, side rail recess 514 and lower lip 512 of the linear boat bumpersystem 400.

47A-E illustrate utility anchor/drag rail bracket cover suitable for usewith the embodiment of anchor chain bracket 366 illustrated in FIG. 28according to one embodiment of the invention. FIG. 47A is a top-planperspective view. FIG. 47B is a side-plan schematic drawing. FIG. 47C isa cross section view taken along line A-A of FIG. 47B. FIG. 47D is atop-plan view and FIG. 47E is a cross section of FIG. 47D taken throughline B-B. FIGS. 47A, 47C and 47E illustrate the upper lip 510, expansionpocket 516, side rail recess 514 and lower lip 512 of the linear boatbumper system 400.

FIGS. 48A-B illustrate one embodiment of a triangle corner deck coverwith no hole 428. FIG. 48A is a perspective top-plan view. FIG. 48B is aperspective bottom-plan view. Corner deck cover 428 is suitable for usewith the embodiment of the large piling bracket 370 illustrated in FIG.30, if no pylon is desired securing the corner bracket 370.

FIGS. 49A-B illustrate one embodiment of a triangle corner deck coverwith a hole 430. FIG. 49A is a perspective top-plan view of cover 430.Corner deck cover 430 is suitable for use with the embodiment of thelarge piling bracket 370 illustrated in FIG. 30, when a pylon is desiredsecuring corner bracket 370.

FIG. 50 is a an exploded view of the support members of a dock unitaccording to one exemplary embodiment of the invention. In thisembodiment, the various frame members, including the side supportmembers 530, the longitudinal support members 532, transverse supportmembers 534 and corner support members 536 may be connected by pre-madetongue 540 and bore 542 couplings. In various embodiments, the couplingscan be fixed by wooden, steel or FRP dowels 544 to connect the framemembers. Of course, those of skill in the art will appreciate that otherfastener types such as bolts or pins may be used. In addition, screwholes 546 may be molded or pre-drilled in the support members 530, 532,534 and 536 for secondary attachment to other support members or forsecuring the support members to the flotation shell 100. While in someexemplary embodiments the support members may be wood, including Douglasfir, lam beams, and metal such as galvanized steel, in various exemplaryembodiments the support members can be molded from composite materialssuch as fiber reinforced plastics/polymers (FRP).

FIG. 51 is a perspective view of the support members 530, 532, 534 and536 pinned using dowels 544 to form the floatation shell frame assembly500. It should be appreciate that, in some embodiments the frameassembly 500 can be assembled first and after assembly dropped into andsecured to the flotation shell 100. In other exemplary embodiments, theframe assembly 500 is secured to the shell during installation.

Those of skill in the art will appreciate that the floating dock units10 can be arranged in multiple configurations with different sizemodular components to arrive at customized modular dock systems for theparticular needs of each marine environment and locale. Further, whilethe linear boat bumper system 400 described herein is particularlysuitable for use with the modular docking system 600, the linear boatbumper system is equally suitable for use on conventional wooden and/ormodular docking systems. As described herein, the linear boat bumpersystem 400 is suitable to accommodate a convention dock deck within theexpansion pocket 516 and a convention side rail within the side railrecess. Moreover, regularly spaced lag-nut holes 518 allow for thelinear bumper system 400 to be secured directly to any underling siderail of any dock system. Furthermore, the linear dock system 400 beingfabricated out of suitable polymer materials is easily customized to fitany length of previously constructed dock system.

Various exemplary embodiments of devices and compounds as generallydescribed above and methods according to this invention will beunderstood more readily by reference to the following examples, whichare provided by way of illustration and are not intended to be limitingof the invention in any fashion.

What is claimed is:
 1. A modular floating dock unit comprising: i) amolded flotation shell; and ii) one or more support members wherein themolded floatation shell is designed and configured to nest within one ormore other floatation shells for shipment and storage.
 2. The modularfloating dock unit of claim 1, further comprising: a foam decking piecedesigned and configured to mate with the floatation shell.
 3. Themodular floating dock unite of claim 2, further comprising a water-tightretainer ring, designed and configured to fit in between the decking andthe flotation shell.
 4. The modular floating dock unit of claim 3,wherein the decking piece is mounted on the flotation shell with thewater-tight retainer ring therebetween creating a water-tight flotationchamber.
 5. The modular floating dock unit of claim 1, wherein the oneor more support members are supported by support columns molded in theflotation shell.
 6. The modular floating dock unit of claim 5, whereinthe support member is enclosed in a water-tight compartment.
 7. Themodular floating dock unit of claim 5, wherein the one or more supportmembers are wooden, laminate, metal or composite.
 8. The modularfloating dock unit of claim 7, wherein the composite support members arefiber reinforced plastics/polymers (FRP).
 9. The modular floating dockunit of claim 8, wherein the FRP fibers comprise fiberglass, carbonfibers, aramid fibers, boron fibers, basalt fibers, wood fibers, flaxfibers and hemp fibers.
 10. The modular floating dock unit of claim 8,wherein composite resins include epoxy, vinyl esters, polyesters,polyurethane, propylene, virgin high density polyethylene and recycledhigh density polyethylene.
 11. The modular floating dock unit of claim1, further including an attachment mechanism for connecting the unit toone or more modular floating dock units.
 12. A modular floating dockunit comprising: a molded flotation shell designed and configured tonest within one or more other floatation shells for shipment andstorage.
 13. The modular floating dock unit of claim 12, furthercomprising: a foam decking piece designed and configured to mate withthe floatation shell.
 14. The modular floating dock unit of claim 12,further including a water-tight retainer ring interposed between themolded floating shell and the foam decking piece.
 15. The modularfloating dock unit of claim 14, wherein an interior space iswater-tight.
 16. The modular floating dock unit of claim 15, furtherincluding one or more support members.
 17. The modular floating dockunit of claim 16, wherein the support members are wooden, laminate,metal or composite.
 18. The modular floating dock unit of claim 11,wherein the composite support members are fiber reinforcedplastics/polymers (FRP).
 19. The modular floating dock unit of claim 12,wherein the FRP fibers comprise fiberglass, carbon fibers, aramidfibers, boron fibers, basalt fibers, wood fibers, flax fibers and hempfibers.
 20. The modular floating dock unit of claim 11, wherein thecomposite resins include epoxy, vinyl esters, polyesters, polyurethane,propylene, virgin high density polyethylene and recycled polyethylene.21. A modular floating dock system comprising a plurality of connectedfloating dock units according to claim 1.